WORK METHOD STATEMENT FOR

WATERPROOFING ACTIVITES

PROJECT: DSR WORLD @ FILMNAGAR

SUBMITTED BY: FOSROC CHEMICALS

UG TANKS/WATER RETAINING STRUCTURES AREAS WATERPROOFING WORK METHOD
STATEMENT:

Contents

SYSTEM – FOSROC BRUSHBOND ULTRAFLEX

1. Scope of work

2. Recommended System

3. System Proposal

4. Material Information and Details

Note: Photos are for reference purpose only and do not represent the actual site conditions.
Fosroc Chemicals (India)
Private Limited
Embassy Point, No. 150
2nd Floor | Infantry Road
Bangalore – 560 001

[Link]

1. SCOPE OF WORK

Supply & Apply of FOSROC Two-Component Acrylic Polymer Modified High Performance &
ultra-flexible elastomeric waterproofing membrane system for concrete and masonry surfaces
consist of powder and liquid acrylic emulsion which is easily brushable.

2. RECOMMENDED SYSTEM- FOSROC BRUSHBOND ULTRAFLEX

Brushbond UltraFlex is a two-component polymer modified waterproof membrane which is

supplied in ready-mix kits. When mixed, an easily brushable coating is produced. It can simply be
applied by a stiff brush, roller, or trowel to obtain the desired thickness.

Brushbond UltraFlex consists of specially selected cements, graded hard wearing aggregates and
additives supplied in powder form together with a liquid component of polymers providing
exceptional adhesion, resiliency, flexibility, toughness and durability and confirms to the following
standards:

● DIN 1048, Part 5, 1991

● ISO 7783:2018

● ASTM D412 : 2013

● Brushbond UltraFlex is deemed to be suitable for use with potable water sources as tested
as per USFDA CFR 175-300

The product is designed to reface and even out variations in concrete and masonry surfaces and
bridgeshrinkage cracks. It provides a seamless, flexible waterproof coating suitable for water tanks,
reservoirs, drainage culverts basements and roofs. The product provides a tough durable water
resistant coating which can withstand light pedestrian traffic and also has excellent weather
resistance.
Few Typical Properties & Advantages

Adhesion to substrate (ASTM D4541:2002) >1n/mm2

Shore A hardness (ASTM D2240:2010) 79

Rapid Chloride Permeability ASTM C 1202 Very Low

Elongation at break ASTM D 412:2013 >150%
Crack Bridging ASTM C 1305 1 mm

Features & Benefits

● Excellent barrier to carbon dioxide, chloride and sulphate ions.

● Allows water vapour to escape from the structure.

● Waterproof-suitable for water retaining structures.

● Non Toxic - ideal for potable water tanks.

● Flexible, with thermal expansion similar to concrete.

● Excellent bond to concrete and masonry.

● Good crack accommodation capacity.

● Minimum surface preparation needed and low labour.

Note: Total thickness approx. 1 mm. for Brushbond Ultraflex. Consumption figures are a guide only and may be
higher in rough or porous substrates.,

SEQUENCE OF WORK FLOW.

STEP-1: SURFACE PREPARATION

STEP-2: BORE PACKING

STEP-3: COVING

STEP-4: PREPOND TEST

STEP-5: TREATING CRACKS AND CONSTRUCTION JOINTS

STEP-6: PRESSURE GROUTING

STEP-7: MIXING OF BRUSHBOND ULTRAFLEX

STEP-8: APPLICATION OF BRUSHBOND ULTRAFLEX

STEP-9: PROTECTION SCREED/PLASTER

SYSTEM PROPOSAL

Section A : General Comments

High temperature working

It is suggested that, for temperatures above 35°C, the following guidelines are adopted as good
working practice:

(i) Store unmixed materials in a cool (preferably temperature controlled) environment, avoiding
exposure to direct sunlight.

(ii) Keep equipment cool, arranging shade protection if necessary. It is especially important
to keepcool those surfaces of the equipment, which will come into direct contact with the material
itself.

(iii) Try to avoid application during the hottest times of the day, arrange temporary
shading asnecessary.

(iv) Make sufficient material, plant and labour available to ensure that application is a
continuousprocess.

Equipment:

It is suggested that the following list of equipment is adopted as a minimum requirement

Protective clothing : Protective overalls, Good quality gloves, goggles and face
maskPreparation equipment : Electric or pneumatic breaker, wire brush

Mixing equipment : 1 KW slow speed drill, 400 or 500 rpm, plus Fosroc propeller

agitatorApplication equipment : Stiff brush, Suitable spray equipment

Section B : Application Method

1.0 Surface preparation

Attention to full and proper preparation of the substrate is essential for complete adhesion.

1.1 All surfaces should be dry and free from contamination such as oil, grease, loose particles,
decayed matter, moss, algal growth, laitance, and all traces of mould release oils and curing
compounds. This is best achieved by lightly grit blasting the surface.

1.2 Spalled and deeply disintegrated concrete should be removed to sound concrete and
repaired witha Fosroc repair system.

1.3 All surfaces to be treated with Brushbond UltraFlex must be pre-wetted with clean water to achieve
Surface Saturated Dry Conditions.
2. Bore Packing:

Preparing the inside surface of core and PVC by roughening using suitable file to get better
adhesion prior to packing works.

If the core cut is more than 100mm then use cutter machine to cut on the corner of core cut at
every25mm depth to have a proper adhesion with the non-shrink grout.

Cleaning the surface by wire brushing followed water jet to remove any laitance or loose flaky particles.
Providing necessary formwork for packing the bore using suitable arrangement (depending upon
site conditions).
Apply one coat of Nitobond SBR Latex/ Nitobond EP to PVC pipe and
apply one coat of Nitobond SBR latex to the surface of concrete
thereby sprinkle sand on the substrate when it is in tacky condition to
form rough surface for betteradhesion with non-shrink grout.

Closing the gap between the concrete surface and the pipes with quick
setting cement Fosroc Renderoc Plug from underneath or using a
shutter frame for support of packing material.

Packing the gap using non-shrink cement g r o u t using Conbextra GP2.

Typical Properties Compressive strength at 28day as per BS 1881

45N/mm2, completely as per the manufacturer’s Instruction.

3.0 Coving

Coving at the junction of Horizontal and vertical offsets

with CM 1:4 admixed with Conplast WL Xtra

@125ml/bagof cement. Prior to start making coving the

junction point needs to be applied with Nitobond SBR

Latex followed bymaking coving of required sizes as per

site condition.

4.0 Pre Pond Test

• Bunds needs to be made on the slab and shall be filled with water covering upto the depth of pipe
for minimum of 48 Hours (2 days) to check leakage or dampness from the bottom of slab from
core pack area and corner junction.

• If any leakages found then need to do identify the source of leakages. Mark the source and treat
it from positive side or negative side.
 5.0 Treating the Cracks, Construction Joints and concrete voids:

Chase opening the Construction Joints by providing “U” groove of 20 mm

x 20 mm, removing the dust and clean the designated area fill the
prepared surface using Polymer modified mortar (Cement Mixed with
Nitobond SBR latex in required consistency) or Non Shrink Grout GP 2 as
per the site conditions completely as per the manufacturer’s
recommendation.

Cleaning of the tie rod holes and filling the same upto 30 mm depth with
Non – Shrink Grout Conbextra GP 2 for the same.

6.0 Pressure Grouting-In case of Leakages

• Pressure grouting to be done from under side of the slab.

• Drilling Hole & fix PVC nozzle pipe using Renderoc Plug.

• Injecting using cement slurry mixing with grout material Fosroc Cebex 100.

• Dosage: 225 gm per bag of 50Kg cement and adding 15 Litres of water and pumping with
40PSIhand operated grouting pump in required consistency until refusal.

• Water Ponding after Leakage Treatment: Water Ponding test to be done for 48 Hours (2days)
tocheck for any further leakages if any. – In case of water retaining structures, water flooding
test is to be done.

• If there is no leakages found then cut projected nozzles and seal off the gap with Renderoc Plug.

7.0 Mixing

● Pour Brush Bond Ultraflex polymer into a suitable mixing vessel

● Add the powder component of 15 kg & Liquid component of 10 kg into the vessel and mix using a mixing
paddle attached to a slow speed drill(500 rpm).

● While mixing, ensure that the powder component is added gradually to the liquid to avoid lump formation and
mix for 2 to 3 minutes.

● Mix only as much material that can be used within the specified pot life.
 8.0 Application

8.1 Surface to be treated with Brushbond Ultraflex

should be pre- soaked with clean water and should be
damp during application.

8.2 Apply a min of 0.8 kg/sqm in each coat in

perpendicular direction to each other (two coats – 1.6
kg/sqm)

8.3 Ensure correct rates of application are followed,

to obtain best results.

8.4 For brush applications, short stiff brush, preferably 100

– 120mm width is best suitable.

8.5 Allow the first coat to dry before applying the

second coat. The total thickness of the coating has to be
1mm.

7.0 Protective Screed / Plaster

In case of Plaster – 12 mm thick 1:3 cement mortar admixed with Conplast WL Xtra for the vertical
walls.

Screed- Waterproofing membrane needs to be covered with screed with 6mm baby chips by adding
Conplast Wl Xtra @ 125ml per bag cement with necessary slopes towards out let or as per the project
stakeholders recommendation – thickness of slope shall be done as per the recommendation from the
client.

Provisions by Client:

● Lights to be provided in the tanks during waterproofing works

● Ventilation fan to be provided for ease of flow of air

● Water to be filled in the tank for the flooding test

● Tie rod holes, sleeves to be removed and the oil/grease is to be cleaned and handed over for
packing the same with grout material which can have better adhesion and bonding to concrete

● Post waterproofing and screeding, enough time to be provided for the area to become dry for the
application of epoxy liners
Treatment around Pipe Penetration Areas:

Bore Packing: Please refer the section details above.

 Preparing the inside surface of core and PVC by roughening using suitable file to get better

adhesion prior to packing works.

 Cleaning the surface by wire brushing followed water jet to remove any laitance or loose flaky

particles. Providing necessary formwork for packing the bore using suitable arrangement

(depending upon site conditions).

 Applying a coat of styrene- butadiene based polymer coating using Nitobond SBR to enhance

adhesion between the packing material and other surfaces.

 Packing the gap using non-shrink cement polymer-based grout using Conbextra GP2 up to the

surface of the bore whilst the Nitobond SBR is in tacky state.

Work Method Statement for the epoxy liner coating of Water Retaining Structures:

Application of Nitocote EP405 for UG Tanks (Suitable for potable water storage):

 Surface Preparation:

 Removing all loose particles, grease, oil and other foreign matter over the substrate before application of
the epoxy coating
 Any cracks are to be repaired by making a U groove of 6 – 8 mm depth x 5 mm width and filling the same
with Non – Shrink Grout of Conbextra GP 2 along with bond coat of Nitobond SBR Latex

 Mixing

 The contents of the resin base tin should be thoroughly stirred to disperse any possible settlement.
 The entire contents of the hardener should be poured into the base container, and the two materials
mixed thoroughly until both uniform color and consistency are obtained.
 It is recommended that the two components are mixed together mechanically: using a slow speed,
electric drill, with a mixing paddle.
 Mixing should be carried out continuously for 3 to 5 minutes.

 Application

 Whilst Nitocote EP405 can be applied to damp surfaces; running water must be excluded from the
work area during both application and curing of the product.
 Nitocote EP405 can be hand-applied using a brush or roller.
 The first coat should be firmly applied and scrubbed well into the surface, ensuring that a continuous
film results of uniform thickness.
 The second coat will cover more readily than the first and should be applied within 18 hours of
application of 1st coat.
 Application shall be done at a forced coverage of 0.2 litres per sqm for the entire area in two coats in
perpendicular direction to each other to form a coating which shall have a DFT of 200 microns.

 Disposal of used Packing Material & Safety precautions

 Do not breathe vapor/spray directly

 Wear the respirator mask, eye protection, Nitrile gloves
 Used empty drums (Ensure completely drained out the material) dispose through approved vendor only
Application of Nitocote ET 550 (Epoxy liner coating for STP Tanks):

 Surface Preparation:

 Removing all loose particles, grease, oil and other foreign matter over the substrate before application of
the epoxy coating
 Any cracks are to be repaired by making a U groove of 6 - 8 mm depth and 5 mm width and filling the same
with Non – Shrink Grout of Conbextra GP 2 along with bond coat of Nitobond SBR Latex

 Mixing

 The contents of the resin base tin should be thoroughly stirred to disperse any possible settlement.
 The entire contents of the hardener should be poured into the base container, and the two materials
mixed thoroughly until both uniform color and consistency are obtained.
 It is recommended that the two components are mixed together mechanically: using a slow speed,
electric drill, with a mixing paddle.
 Mixing should be carried out continuously for 3 to 5 minutes.

 Application

 Nitocote ET550 may be applied by brush or spray to give uniform finish.

 Application shall be done at a forced coverage of 1.8 – 1.9 litrs per sqm for the entire area in two
coats in perpendicular direction to each other to form a coating which shall have a DFT of 350
microns.

 Disposal of used Packing Material & Safety precautions

 Do not breathe vapor/spray directly

 Wear the respirator mask, eye protection, Nitrile gloves
 Used empty drums (Ensure completely drained out the material) dispose through approved vendor only